Table of Contents
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Models
UB90-125
UB90-150
UB90-175
UB90-200
An ISO 9001-2008 Certified Company
UB 90 125-200 SERIES II
GAS-FIRED, DIRECT VENT,
CONDENSING, HOT WATER BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Manufactured by:
ECR International, Inc.
2201 Dwyer Avenue, Utica NY 13504-4729
web site: www.ecrinternational.com
P/N 240009432 Rev. D [09/2013]
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Table of Contents
Related Manuals for UTICA BOILERS UB90-125
Summary of Contents for UTICA BOILERS UB90-125
- Page 1 UB 90 125-200 SERIES II GAS-FIRED, DIRECT VENT, CONDENSING, HOT WATER BOILER Models INSTALLATION, OPERATION & UB90-125 MAINTENANCE MANUAL UB90-150 UB90-175 UB90-200 Manufactured by: ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13504-4729 web site: www.ecrinternational.com An ISO 9001-2008 Certified Company...
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Page 2: Table Of Contents
TABLE OF CONTENTS 1 - Boiler Ratings & Capacities ...... 3 IMPORTANT: Read following instructions COMPLETELY before installing!! 2 - Safe Installation And Operation ....5 3 - Locating The Boiler ........ 6 WARNING 4 - Near Boiler Piping ........8 Fire, explosion, asphyxiation and electrical shock 5 - Water Chemistry &... -
Page 3: Boiler Ratings & Capacities
1 -BOILER RATINGS & CAPACITIES Figure 1 - Boiler Jackets Opening for Air Vent Opening for Relief and Expansion Tank Valve Discharge Pipe Connection Standard Supply & Return Openings Vent Connection Junction Box for 120 VPower & 1 1/4 NPT Connections (2”... - Page 4 1 - BOILER RATINGS & CAPACITIES Ratings shown are for sea level applications. Boiler automatically derates input as altitude increases. No alterations to boiler are required for altitudes above sea level. Table 2 - NATURAL GAS 200,000 175,000 150,000 125,000 Nominal Input 3”...
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Page 5: Safe Installation And Operation
2 - SAFE INSTALLATION AND OPERATION Installers - Follow local regulations with respect to WARNING installation of CO (Carbon Monoxide) Detectors. Follow Improper installation, adjustment, alteration, service maintenance recommendations in this manual. See or maintenance could result in death or serious “Maintenance And Cleaning”... -
Page 6: Locating The Boiler
3 - LOCATING THE BOILER Locating The Boiler Boiler shall be installed such that automatic gas ignition system components are protected from water Select level location, central to piping systems served (dripping, spraying, rain, etc.) during operation and and close to vent and air intake terminals as possible. service (circulator replacement, condensate trap, Manufacture recommended accessibility clearances, if control replacement, etc.). - Page 7 3 - LOCATING THE BOILER After it has been determined each appliance remaining connected to common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans and any other gas-burning appliance to their previous condition. Any improper operation of common venting system should be corrected so installation conforms with the National Fuel Code, ANSI Z223.1/NFPA 54.
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Page 8: Near Boiler Piping
4 - NEAR BOILER PIPING General Instructions Dielectric Isolation Packaged boiler is furnished with iron piping in front Two (2) 1-1/4” X 1-1/4” female to female dielectric boiler section for supply and return connections. isolation unions are supplied. Install dielectric isolation unions at boiler supply line and return line. - Page 9 4 - NEAR BOILER PIPING Expansion Tank And Make-Up Water Figure 3 - Relief Valve Discharge Piping • Determine required system fill pressure, design temperature, and water content. • Boiler contains 2.6 gallons (U.S.). Size expansion tank RELIEF VALVE accordingly. Consult expansion tank manufacturer for proper sizing information.
- Page 10 4 - NEAR BOILER PIPING Figure 4 - Diaphragm Type Expansion Tank Piping DIELECTRIC UNION Figure 5 - Single Zone Boiler Piping DIELECTRIC UNIONS DIELECTRIC UNIONS...
- Page 11 4 - NEAR BOILER PIPING Figure 6 - Multi-zone Boiler Piping with Circulators ZONE SERVICE VALVE FLOW CHECK SUPPLY TO VALVE ZONES ZONE SERVICE VALVE CIRCULATORS FLOW CHECK VALVE PRESSURE REDUCING VALVE GATE VALVE CAN VENT REDUCED PRESSURE BACKFLOW PREVENTER AIR SCOOP FEED WATER...
- Page 12 4 - NEAR BOILER PIPING Condensate Drain Requirements • Condensate pump with reservoir (not furnished) may be used to remove condensate to drain line (sanitary Pitch condensate drain line down to floor drain at line) above boiler if floor drain is not available or is minimum of ¼”...
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Page 13: Water Chemistry & Antifreeze Guidelines
5 - WATER CHEMISTRY AND GENERAL ANTIFREEZE GUIDELINES • This boiler is designed for closed loop hydronic heat WARNING system only. Boiler is not suitable for natural gravity Fire, explosion, asphyxiation hazard. Inadequate type installations, or any other open type system. dielectric isolation, incorrect water treatment or antifreeze application may cause damage to boilers General Guidelines When Using Antifreeze... - Page 14 5 - WATER CHEMISTRY AND GENERAL ANTIFREEZE GUIDELINES Table 5 - Compatible Aluminum Antifreeze & Inhibitor Suppliers Noble Company P. O. Box 350 Grand Haven, MI 49417 Noburst AL Antifreeze www.noblecompany.com Tel: 800-878-5788 Fax: 231-799-8850 Rhomar Water Management, Inc. P. O. Box 229 Rhogard Antifreeze &...
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Page 15: Combustion Air/ Vent Requirements
6 - COMBUSTION AIR/ VENT REQUIREMENTS Combustion Air/Vent Pipe Requirements Figure 10 - Sidewall Vent/Intake Terminations Boiler requires dedicated direct vent system. Direct vent Single Boiler system, all air for combustion is taken directly from outside Application atmosphere, and all flue products are discharged to outside 12"... - Page 16 6 - COMBUSTION AIR/ VENT REQUIREMENTS WARNING Figure 13 - Concentric Vent Roof Installation Fire, explosion, asphyxiation hazard. Solvent cements are combustible. Keep away from heat, sparks, or open flame. Use only in well ventilated areas. Avoid breathing in vapor or allowing contact with skin or eyes.
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Page 17: Combustion Air And Vent Pipe
7 - COMBUSTION AIR AND VENT PIPE Connections And Termination WARNING Installation must conform to requirements of authority Use of cellular core PVC (ASTM F891), cellular core having jurisdiction or, in absence of such requirements, CPVC, or Radel (polypenolsulfone) in venting ®... - Page 18 7 - COMBUSTION AIR AND VENT PIPE Table 7 - Combustion air and vent pipe fittings must conform with the following: Item Material USA Standard Canadian Standard UL1738 ULC S636 (Pipe & Fittings) ASTM D1785 ULC S636 ASTM D2241 Exhaust (Fittings) D2466 and/or UL1738...
- Page 19 7 - COMBUSTION AIR AND VENT PIPE • Every outside wall penetration shall be permanently NOTICE sealed to prevent entry of combustion products into building. Exhaust transition from 2” pipe to 3” pipe must be • Venting that discharges flue gases perpendicular to made in vertical run.
- Page 20 7 - COMBUSTION AIR AND VENT PIPE Installation Recommend all pipes be cut, prepared, and pre- assembled before permanently cementing any joint. Rigid supports cause excess noise in vent piping. Attach combustion air intake piping to supplied 2” coupling on CVI gas valve. Attach vent piping to furnished 2”...
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Page 21: Gas Supply Piping
8 - GAS SUPPLY PIPING Check Gas Supply Install sediment trap upstream of gas controls. Use two pipe wrenches when making connection to gas Table 8 - Gas Supply Pressure valve to keep it from turning. Pressure Natural Gas Propane Gas Install manual main shutoff valve in vertical pipe about 5 feet (1.5m) above floor outside boiler jacket. -
Page 22: Electrical Wiring
9 - ELECTRICAL WIRING WARNING Figure 16 - Field Wiring Connection Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury. NOTICE Use copper conductors only. Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. - Page 23 9 - ELECTRICAL WIRING Thermostat Installation AVOID THE FOLLOWING • Follow instructions included with your thermostat. Corners • Locate thermostat five feet above floor on inside wall. Dead Spots Alcoves • Mount directly on wall or vertically mount on outlet box. Behind doors Thermostat should sense average room temperature.
- Page 24 9 - ELECTRICAL WIRING Figure 17 - Schematic Wiring Connections NOTE: If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 150°C Thermoplastic wire or its equivalent.
- Page 25 9 - ELECTRICAL WIRING Figure 18 - Ladder Wiring Diagram NOTE: If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 150°C Thermoplastic wire or its equivalent.
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Page 26: Controls And Accessories
10 - CONTROLS AND ACCESSORIES See “Troubleshooting” on page 31 for detailed sequences of Figure 20 - Indicator Lights operation and troubleshooting procedures. See separately provided “Repair Parts Manual” for locations of control components and accessories described. Integrated Boiler Control (IBC) •... - Page 27 10 - CONTROLS AND ACCESSORIES Differential Pressure Switches • Furnished relief valve automatically opens at 30 psi • Diaphragm type differential pressure switches are to relieve strain on boiler and heating system from connected by vinyl tubing to gas valve, air inlet increasing pressure.
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Page 28: Startup
11 - STARTUP Water Treatment And Freeze Protection Filling Boiler With Water And Purging Air For Systems With Conventional Closed Type Expansion Tanks Refer to diagrams on “Near Boiler Piping” on pages 9 and Filling Boiler With Water And Purging Air For Systems 10 for more information. - Page 29 11 - STARTUP Operating Instructions WARNING STOP! Read the safety information on this page before If you do not follow these instructions operating this appliance. exactly, a fire or explosion may result Set the thermostat to the lowest setting. causing property damage, personal injury Turn off all electrical power to the appliance.
- Page 30 11 - STARTUP If Burner Appears To Pulsate During Ignition: Turn off boiler power. Shut off gas supply to boiler. Take burner assembly apart by removing combustion air blower and gas valve/venturi assembly from boiler. Visually inspect inside of burner. Look for debris (PVC shavings, etc.).
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Page 31: Detailed Sequence Of Operation
12 - DETAILED SEQUENCE OF OPERATION DRAFT INDUCER TEMPERATURE SAFETY CASTING TEMPERATURE SAFETY SWITCH SWITCH If burner operates when boiler has no water, If draft inducer temperature reaches temperature aluminum boiler sections heat up rapidly. safety switch set-point, safety switch contacts open immediately, closing gas valve (light goes out) Casting temperature safety switch contacts will... - Page 32 12 - DETAILED SEQUENCE OF OPERATION End Of Normal Sequence Of Operation Thermostat ends call for heat. Gas valve and circulator pump are de-energized, valve and flame lights go out. Blower runs for 30 seconds post purge, purge light is on. Blower is de-energized after 30 seconds, purge light shuts off.
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Page 33: Service Hints
12 - DETAILED SEQUENCE OF OPERATION SERVICE HINTS POWER ON STAND BY THERMOSTAT CALLS FOR HEAT IF MAIN BURNER DOES NOT PROVE FLAME IN 3 TRIALS, CONTROL LOCKOUT. VALVE/FLAME LIGHT BLINKS , CIRCULATOR RESET IS REQUIRED. THIS PROBLEM IS A ENERGIZES THRU RESULT OF NOT ESTABLISHING FLAME SIGNAL. -
Page 34: Sequence Of Operation Diagnostics
13 - SEQUENCE OF OPERATION DIAGNOSTICS Sequence Of Operation Diagnostics Follow sequence using the diagnostic indicator lamps on Integrated Boiler Control (IBC). See “Controls And Accessories” on page 26 for normal sequence of operation. Detailed sequence of operation containing potential faults can be found in service hints section. - Page 35 13 - SEQUENCE OF OPERATION DIAGNOSTICS System Status Indicator lights track operating sequence. If system locks out, lights indicate point in sequence of operation were lockout occurs. Refer to following pages for detailed troubleshooting procedures. LIGHT STATUS INDICATES IBC is energized through 24 volt transformer. POWER IBC is not energized.
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Page 36: Checkout Procedure & Adjustments
14 - CHECKOUT PROCEDURE & ADJUSTMENTS Inspect Venting & Air Intake System - Operate boiler. Test Other Safety Controls Verify all vent/air intake connections are gas-tight and If boiler is equipped with low water cut off, manual reset water-tight. Repair any leaks immediately. high limit, or additional safety controls, test for operation as outlined by control manufacturer. - Page 37 14 - CHECKOUT PROCEDURE & ADJUSTMENTS Adjustments And Checkout Set Thermostat To Desired Temperature Set thermostat to desired room temperature and observe Appliance should operate between 8.5 And 10% CO2. several complete cycles to verify proper operation. Verify boiler is operating in this range. Follow steps below. NOTICE Final Review And Sign-Off Under all conditions CO levels should not exceed...
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Page 38: Troubleshooting
15 - TROUBLESHOOTING High Limit Control and LWCO Figure 21 - LED Legend LED Legend and LWCO Test Button HI TEMP illuminates when boiler water temperature reaches high limit setting. Remains lit until water temperature falls 10°F. Limit prevents burner operation while this LED is on. - Page 39 15 - TROUBLESHOOTING Troubleshooting Flow Chart - High Limit Control And LWCO Burner Will Not Fire See Flow Chart, this page. If installed with indirect water heater, insure end switch in relay box controlling indirect water No or Insufficient heater is properly connected to Cable 2. This will insure domestic water calls are prioritized. If Domestic Hot Water Cable 2 is not used, turn Economy Feature OFF.
- Page 40 15 - TROUBLESHOOTING Initial Service Checks WARNING Before Troubleshooting: Fire, explosion or shock hazard may cause death or A. Verify circuit breaker is on or fuse is OK at electrical serious injury. Do not attempt to modify physical or panel. electrical characteristics of this boiler in any way.
- Page 41 15 - TROUBLESHOOTING Troubleshooting Chart 1...
- Page 42 15 - TROUBLESHOOTING Troubleshooting Chart 2...
- Page 43 15 - TROUBLESHOOTING Troubleshooting Chart 3 CHART 1 OPEN CHECK FOR VAC BLOWER STARTS BETWEEN TERMINALS 1 AND 3 REPLACE IBC AT CONNECTOR CN4 ON IBC CHECK FOR 120 VAC AT REPAIR/REPLACE BLOWER LEADS ON WIRING WIRING FROM IBC HARNESS TO BLOWER REPAIR/REPLACE BLOWER...
- Page 44 15 - TROUBLESHOOTING Troubleshooting Chart 4 CHART 3 CHECK FOR 120 VAC IGNITER/SENSOR WARMS BETWEEN TERMINALS 1 UP AND GLOWS AND 2 AT CONNECTOR YELLOW/ORANGE REPLACE IBC CN1 ON IBC (DURING DURING 20 SECOND IGNITER WARM UP) WARM UP CHECK FOR 120 VAC AT IGNITER/SENSOR LEADS REPAIR/REPLACE WIRING ON WIRING HARNESS...
- Page 45 15 - TROUBLESHOOTING Troubleshooting Chart 5...
- Page 46 15 - TROUBLESHOOTING Troubleshooting Chart 6 CHART 5 CHART 5 CHART 5 REPLACE GAS CONTROL. NO #3 NO #2 CHECK GAS ORFICICE SIZE. IS GAS ORIFICE SIZE CORRECT. CHECK REPAIR PARTS LIST FOR CORRECT SIZE. IS GAS ORIFICE CLEAR OF BLOCKAGE. RUNS FOR 25-50 SECONDS, THEN TURNS OFF.
- Page 47 15 - TROUBLESHOOTING Differential Air Pressure Switch Check Figure 22 - Locations Of Connection Points Required To Check Differential Air Pressure Differential air pressure switch is safety device which prevents boiler from firing if there is air intake, boiler heat exchanger or vent blockage.
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Page 48: Maintenance And Cleaning
16 - MAINTENANCE AND CLEANING Acidic nature of flue gasses condensing on aluminum boiler Daily During Heating Season sections cause formation of aluminum oxide. This oxide Check for and remove any obstruction to flow of formation is normal, is generally uniform throughout boiler combustion air or venting of flue gases. - Page 49 16 - MAINTENANCE AND CLEANING H. Aluminum oxide deposits are water soluble and DANGER may be rinsed away with spraying or running Before servicing, turn off electrical power to boiler water. at service switch. Close manual gas valve to turn Use flexible handle nylon brush to loosen sediment gas supply OFF to boiler.
- Page 50 • This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater. • This boiler is equipped with a tankless coil. UTICA BOILERS 2201 Dwyer Avenue Utica NY 13501 web site: www.ecrinternational.com...